Ophthalmic device formed by additive fabrication and method thereof

Abstract

An ophthalmic device is formed by additive fabrication, the optical device having an optical surface with a surface roughness on the order of less than 10 microns. A method is provided for making an ophthalmic device including an optical surface having a surface roughness of less than 10 microns by depositing on a stage in a first relative position a first lamina of particulates having a size less than 10 microns and in select configurations less than two microns and certain configurations less than one micron, and, synergistically stimulating the first lamina of particulates to form a first solidified layer.

The invention claimed is: 
     
       1. An ophthalmic device having an optical surface and a plurality of additive fabrication lamina, wherein one of the plurality of additive fabrication lamina forms at least a portion of the optical surface. 
     
     
       2. The ophthalmic device of  claim 1  wherein each of the plurality of additive fabrication lamina is a UV curable material. 
     
     
       3. The ophthalmic device of  claim 1  wherein each of the plurality of additive fabrication lamina is an IR curable material. 
     
     
       4. The ophthalmic device of  claim 1  further comprising a chemical binder. 
     
     
       5. The ophthalmic device of  claim 1  further comprising a removable sacrificial material arranged to support the optical surface. 
     
     
       6. The ophthalmic device of  claim 5  wherein the removable sacrificial material is a wax. 
     
     
       7. The ophthalmic device of  claim 1  wherein each of the plurality of additive fabrication lamina has a thickness of less than 1 micron. 
     
     
       8. The ophthalmic device of  claim 1  wherein the ophthalmic device is a lens. 
     
     
       9. The ophthalmic device of  claim 1  wherein the ophthalmic device is a corrective lens. 
     
     
       10. The ophthalmic device of  claim 1  wherein the plurality of additive fabrication lamina are printed. 
     
     
       11. A corrective lens consisting of a plurality of printed layers, wherein at least one of the plurality of printed layers forms at least a portion of an optical surface of the corrective lens. 
     
     
       12. An ophthalmic device having an optical surface, the ophthalmic device consisting of a plurality of additive fabrication lamina, wherein one of the plurality of additive fabrication lamina forms at least a portion of the optical surface.